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AEROGENERADORES
2017
AEROGENERADORES
INTRODUCCIN
FUNCIONAMIENTO DE UN AEROGENERADOR
Un aerogenerador es, de forma muy simplificada, un rotor acoplado a una turbina que es capaz
de extraer la energa cintica del viento y convertirla en energa elctrica.
El diseo del rotor de un aerogenerador ms cotidiano hoy en da es el tripala dans (por motivos
de estabilidad de la turbina, peso, reduccin de tensin y fatigas etc.), con el rotor emplazado a
barlovento (por delante de la torre, para evitar que sta desve el propio aire incidente). El
dimetro del rotor, junto con el tamao del generador, multiplicador y altura a la que est
situado definirn la energa que el aerogenerador puede extraer.
PARTES QUE LO CONFORMAN
Un sistema de generacin elica est formado por otros subsistemasmenores que realizan una
determinada funcin.
1. Gndola
Es una estructura metlica donde se monta el generador elctrico. Usualmente, la gndola est
construida a partir de perfiles estructurales de acero soldados y placas de fibra de vidrio. Su
dimensin y peso depende de las cargas que debe soportar. Sobre esta estructura va colocada
una cubierta general cuyo propsito es proteger a los componentes del sistema contra los
efectos del medioambiente.
2. Rotor
Su funcin es convertir la energa cintica del viento en la energa mecnica que se utiliza para
impulsar el generador elctrico. Los subsistemas bsicos que constituyen el rotor son las aspas
y el buje.
La fuerza del viento ocasiona que un rotor de eje horizontal gire a una cierta velocidad angular.
El flujo elico que incide sobre las palas de un rotor en movimiento depende, entre otros
factores, de la relacin entre la velocidad lineal de la pala y la velocidad del viento.
3. Palas
Las palas o aspas estn fabricadas y diseadas con el fin de alcanzar un balance ptimo en la
captacin eficaz de la energa del viento y lograr una mnima carga sobre la turbina, al mismo
tiempo que un funcionamiento libre de problemas. Los materiales de construccin de las palas
deben ser capaces de soportar las cargas mximas sin perjuicios al generador a lo largo de su
vida til, como tambin tener un peso mnimo para aminorar las cargas gravitatorias e inerciales,
adems de aminorar costos. Los materiales empleados para la construccin de las aspas son
madera, acero, aluminio o fibra de vidrio.
4. Buje
Es la parte que une las palas del rotor con el eje. Es el elemento donde se unen las palas y
mediante el cual la potencia captada se transmite al eje principal.
5. Eje
Conecta el buje del rotor al generador. Esta gira y permite el funcionamiento del generador
elctrico.
6. Generador elctrico
Es una de las partes ms importantes del generador elico. Transforma la energa mecnica del
eje, en energa elctrica.
Los generadores elctricos ms utilizados para la configuracin de sistemas elicos han sido los
generadores asncronos. Los generadores asncronos son motores de induccin que se utilizan
en forma inversa hacindolos girar a unavelocidad mayor que su velocidad de sincronismo.
Cuando a un motor de induccin, conectado a la red elctrica, se le hace girar por encima de su
velocidad de sincronismo, mediante la aplicacin de un par motriz en su eje de rotacin, la
potencia mecnica aplicada se transforma en energa elctrica. A partir de la velocidad de
sincronismo, la magnitud de la potencia elctrica que se entrega a la red aumenta en funcin de
la ocurrencia de cientos de mayor intensidad.
Actualmente, cerca del 95% de los aerogeneradores comerciales son sistemas de velocidad
constante con generadores elctricos asncronos.
7. Torre
Parte del aerogenerador que soporta la gndola y el rotor. Su principal funcin es estructural. El
grosor y la altura de la torre varan en funcin de las caractersticas de la turbina. Por ejemplo,
una turbina de 2000 KW tendr una torre de entre 60 y 100 metros
BIBLIOGRAFIA
PAGINAS WEB
https://www.enerlim.com/uploads/documentos/Tecnologia.pdf
https://es.slideshare.net/rodrix_12_12/informe-aerogeneradores-garbi
https://www.master-builders-solutions-
basf.es/alfresco/d/d/workspace/SpacesStore/eeca5f6d-4cb3-44fe-943b-
48ac6eb3594d/parques-eolicos.pdf?guest=true
ANEXOS
0
Colombia
Ecuador
2S
2S
5
TUMBES
5
4S
4S
LORETO
PIURA AMAZONAS
5
6S
6S
5
LAMBAYEQUE
5
CAJAMARCA
5
SAN MARTIN
5
Brazil
8S
8S
LA LIBERTAD
5
5
ANCASH HUANUCO
5
Oc
10S
10S
5 UCAYALI
ano
PASCO
P ac
5
f ic
o
JUNIN
LIMA
12S
12S
CALLAO
5 5 MADRE DE DIOS
14S
3-4
APURIMAC
4-5 5 AYACUCHO
ICA
5-6
6-7
7-8 PUNO
8-9
Bolivia
9 - 10
AREQUIPA
5
16S
16S
> 10
18S
LIMA - PER 5
OCTUBRE DE 2008
Chile
Base cartogrfica: Escala 1 : 6,000,000
Carta Nacional del Per, Limites departamentales 0 30 60 120
Proyeccin: Geogrfica, Datum WGS84
Km
20S
0
Colombia
Ecuador
2S
2S
5
TUMBES
5
4S
4S
LORETO
PIURA AMAZONAS
5
6S
6S
5
LAMBAYEQUE
5
CAJAMARCA
5
SAN MARTIN
5
Brazil
8S
8S
LA LIBERTAD
5
5
ANCASH HUANUCO
5
Oc
10S
10S
5 UCAYALI
ano
PASCO
P ac
5
f ic
o
JUNIN
LIMA
12S
12S
CALLAO
5 5 MADRE DE DIOS
14S
3-4
APURIMAC
4-5 5 AYACUCHO
ICA
5-6
6-7
7-8 PUNO
8-9
Bolivia
9 - 10
AREQUIPA
5
16S
16S
> 10
18S
LIMA - PER 5
OCTUBRE DE 2008
Chile
Base cartogrfica: Escala 1 : 6,000,000
Carta Nacional del Per, Limites departamentales 0 30 60 120
Proyeccin: Geogrfica, Datum WGS84
Km
20S
0
Colombia
Ecuador
2S
2S
5
TUMBES
5
4S
4S
LORETO
PIURA AMAZONAS
5
6S
6S
5
LAMBAYEQUE
5
CAJAMARCA
5
SAN MARTIN
5
Brazil
8S
8S
LA LIBERTAD
5
5
ANCASH HUANUCO
5
Oc
10S
10S
5 UCAYALI
ano
PASCO
P ac
5
f ic
o
JUNIN
LIMA
12S
12S
CALLAO
5 5 MADRE DE DIOS
14S
3-4
APURIMAC
4-5 5 AYACUCHO
ICA
5-6
6-7
7-8 PUNO
8-9
Bolivia
9 - 10
AREQUIPA
5
16S
16S
> 10
18S
LIMA - PER 5
OCTUBRE DE 2008
Chile
Base cartogrfica: Escala 1 : 6,000,000
Carta Nacional del Per, Limites departamentales 0 30 60 120
Proyeccin: Geogrfica, Datum WGS84
Km
20S
ESP
Operacin
Mantenimiento
Owners Manual
Installation
GB
Operation
Maintenance
Bornay Aerogeneradores, slu P.I. Riu, Cno. del Riu, s/n Tel. +34/965560025 bornay@bornay.com
03420 Castalla (Alicante) Espaa Fax +34/965560752 www.bornay.com
ndice
ndice 2
Datos tcnicos 6
ESP
Montaje 8
La Torre 9
Cableado elctrico 10
Regulador 15
Mantenimiento 25
Preguntas frecuentes 27
Solucin de problemas 30
Anexos 33
Declaracin de conformidad 35
Garanta. 36
ESP
Apreciado cliente,
Al final del manual dispone de sus condiciones de garanta, las cuales dependen
de una correcta instalacin de su aerogenerador, lo cual asegurar el correcto
funcionamiento del mismo y por supuesto el correcto servicio.
Atentamente,
Bornay Aerogeneradores.
Bornay Aerogeneradores, slu P.I. Riu, Cno. del Riu, s/n Tel. +34/965560025 bornay@bornay.com
03420 Castalla (Alicante) Espaa Fax +34/965560752 www.bornay.com
Informacin de su inters:
Bornay 600 Rev 6.0 - P 3
Este manual contiene toda la informacin necesaria para la correcta instalacin
y mantenimiento de su aerogenerador. Para asegurar su correcto
funcionamiento, evitar roturas y peligros, se recomienda que lea atentamente
este manual antes de proceder a realizar la instalacin.
ATENCIN: PRECAUCIN:
Identificacin
Regulador: En el lateral derecho, viene una etiqueta adhesiva que indica las
caractersticas, incluyendo modelo de regulador, modelo de
aerogenerador, voltaje y N de Serie.
1 Timn de orientacin
1 Tubo Cola
1 Carcasa protectora
1 Alternador
ESP
1 Buje
1 Refuerzo buje
2 Palas
1 Cono frontal
1 Juego tornillera
1 Pletina fijacin torre
1 Cuadro control / Regulador.
CUADRO CONTROL/REGULADOR
Bornay 600
Especificaciones tcnicas
Nmero de hlices 2
Dimetro 2 mts.
Material Fibra de vidrio / carbono
ESP
Especificaciones elctricas
Alternador Trifsico de imanes permanentes
Imanes Ferrita
Potencia nominal 600 W
Voltaje 12, 24, 48 v.
RPM @ 1000
Regulador 12v 60 Amp
24v 30 Amp
48v 15 Amp
Velocidad de viento
Para arranque 3,5 m/s
Para potencia nominal 11 m/s
Para frenado automtico 13 m/s
Mxima 60 m/s
Especificaciones fsicas
Peso aerogenerador 38 Kg
Peso regulador 7 Kgr
Embalaje 500 x 770 x 570 mm. 55 Kg
Dimensiones peso 1040 x 270 x 70 mm 4,7 Kg
Total 0,22 m3 59,7 Kgr.
Garanta 3 aos
ESP
Montaje
cableado
Montaje de la Montaje del pruebas de
elctrico funcionamiento
torre aerogenerador
regulador
ESP
vertical y nivelada, para evitar un mal quede totalmente vertical
funcionamiento de su aerogenerador. y nivelada.
En el caso de torres de poca base que precisen tensores, una vez anclada la base
y colocada la torre, se le colocarn 3 4 tensores cuyos soportes se anclarn
firmemente al suelo, generalmente con una base de hormign.
PRECAUCIN:
Cualquier objeto que
entre en contacto con las
hlices en movimiento,
puede daarlas y
desequilibrarlas.
Cableado elctrico
ATENCIN: PRECAUCIN:
No instalar el aerogenerador sin No invertir la polaridad.
conectar primero las bateras y el
regulador. Utilice el cableado adecuado.
ESP
Las recomendaciones mnimas de instalacin as como del cableado entre la
batera y el regulador son:
ATENCIN: PRECAUCIN:
Se recomienda el uso de bateras El uso de una batera inadecuada
estacionaras de Plomo cido puede provocar daos irreparables
abiertas en su aerogenerador
El cuadro de
regulacin, bateras
y posible convertidor
debern estar
colocados en un
punto centralizado
prximo al
consumo, y lo ms
prximo posible
entre ellos.
Para la instalacin del regulador, levantar la tapa inferior del regulador (slo la
pequea que forma un ngulo de 90) quitando los cuatro tornillos que la
sujetan. De este modo, el regulador quedar tal y como se muestra en la
siguiente figura:
PRECAUCIN:
No invertir la polaridad.
ESP
cables. Esta conexin se realiza previa al montaje del aerogenerador, de
lo contrario el aerogenerador debe de estar frenado.
En el caso de que haya que desconectar el regulador por algn motivo, durante
la instalacin o durante la vida til de su instalacin, se han de seguir los pasos
siguientes:
Para determinar la seccin del cable de bajada que se debe utilizar, en funcin
de las caractersticas del aerogenerador y la distancia que le separa de su cuadro
de control, vase la siguiente tabla para cable conductor de cobre:
Seccin mm2 4 6 10 16 25 35 50
Seccin AWG 11 9 7 5 3 1 0
Dimetro (mm) 2.26 2.76 3.57 4.51 5.64 6.68 7.98
Bornay 600 Rev 6.0 - P 14
Dimetro (in) 0.088 0.108 0.141 0.178 0.222 0.263 0.314
ESP
Regulador
ATENCIN: PRECAUCIN:
Con viento fuerte, frenar el Con fuerte viento, no deje
aerogenerador accionando nunca el aerogenerador
intermitentemente el girando en posicin de
interruptor de freno. freno.
El aspecto fsico del panel frontal del regulador es el que muestra la figura
siguiente, en la que se puede apreciar la funcin de cada componente que lo
forma:
Indicador
Ventilador
Indicador
de frenado
Regulador Inclin
Inclin regulator
Indicador Stop
ESP
Batera
Media - Alta
On
Indicador Off
Batera
con voltaje
estable
Indicador
Batera Pantalla de
Baja Interruptor
cristal liquido de frenado
(Display LCD)
Funcionamiento bsico:
ESP
Donde se ve en la lnea superior de la pantalla, el modelo del regulador. De
izquierda a derecha indica: La potencia del aerogenerador, el voltaje del mismo,
y la corriente mxima que acepta. En la lnea inferior, aparece la versin del
sistema.
NOTA:
NOTA: si estando el equipo en estado de FRENO AUTO queremos que este vuelva
de nuevo a su posicin de carga sin tener que esperar a que el voltaje de batera
baje hasta el valor de desactivacin, solamente hay que situar el conmutador
(frenado manual) en posicin ON y retornar a continuacin a la posicin OFF, de
este modo se habr borrado el estado de frenado automtico y el equipo volver
a generar energa de inmediato si existe el viento apropiado, al mismo tiempo se
inicializan los contadores de tiempo e impulsos.
ESP
Cuando se activa el conmutador manual de freno, aparece la indicacin al final
de la segunda lnea y adems queda iluminado el LED de indicador de frenado.
Seales de Aviso:
ESP
La pletina cuenta con una ranura para la
bajada los cables elctricos y seis taladros
para seis tornillos allen M-10 x 40, con
arandelas M-10 en ambas caras y seis
tuercas M-10. El conjunto de tornillos se
suministra en una bolsa separada del resto
de la tornillera y junto a la pletina en el
caso de no haber sido enviada por
anticipado o no adjuntar la torre.
La unin del tubo al alternador consta de dos partes, una es pasante y otra en
forma de brida: Se introduce el tubo de cola en la parte trasera del alternador,
haciendo coincidir los taladros de ambas piezas quedando la ranura del tubo
hacia abajo. En los orificios se instala un tornillo hexagonal M-8 x 60, con dos
arandelas M-8 una en cada parte y una tuerca autoblocante M-8. En la parte
superior se tiene un sistema de apriete en forma de brida. Simplemente habr
que apretar el tornillo que lleva la brida, una vez est en su posicin. Con un
apriete de ambos de 2,5 Kgr.
Carcasa protectora:
ESP
Las hlices, de fibra de vidrio / carbono reforzadas, son la parte en contacto
directo con el viento. Su aerodinmica, diseada especficamente para los
aerogeneradores Bornay, permite el funcionamiento del alternador hacindolo
rodar en funcin de la velocidad del viento.
ATENCIN: PRECAUCIN:
Compruebe que las hlices
Compruebe una vez ms que
estn correctamente
ESP
PRECAUCIN:
Tras su instalacin
Transcurrido 1 mes desde la instalacin del aerogenerador, se recomienda,
reapretar toda la tornillera del aerogenerador.
Permanente
ESP
consejos de mantenimiento:
Cada 6 meses
Rodamientos
El aerogenerador est equipado con rodamientos blindados de gran calidad que
no necesitan mantenimiento. Puede comprobar si giran libremente o por el
contrario se observa algn tipo de roce o vibracin.
Tornillera
Toda la tornillera es de acero inoxidable. Ante la falta de cualquier tornillo en
una revisin de mantenimiento, reemplazarlo inmediatamente antes de que
pueda producir daos mayores.
Hlices
Las hlices de fibra de vidrio / carbono, llevan en el borde de ataque una cinta
protectora de Poliuretano abrasivo.
Esta cinta con el paso del tiempo puede verse afectada por las condiciones
ESP
Amortiguador
El aerogenerador lleva instalado un amortiguador hidrulico que permite la
desorientacin respecto al viento rpidamente, y su vuelta a la posicin normal
lenta, evitando golpes bruscos.
Engrase
El aerogenerador Bornay, consta de 3 partes mviles:
ESP
3.-Se puede desconectar la batera con el aerogenerador en marcha?
Bajo ningn concepto, ya que esta accin puede provocar daos
irreparables en el regulador.
5.- El voltaje que mide el regulador no corresponde con el nivel de batera que
miden otros equipos.
Cada fabricante o incluso cada equipo emplea componentes diferentes y
estos no suelen ser calibrados por cuestin de costes. Puede haber
oscilaciones entre diferentes equipos aunque sean de un mismo
fabricante y modelo.
ESP
En el caso de instalaciones aisladas, este estabilizador/controlador es la
batera.
ESP
activado. mquina. bajadas de la fuerza del
viento.
La pantalla del Batera desconectada. Revisar cableado en la
regulador no muestra parte de continua. Y
nada. comprobar que llega
tensin al regulador.
Circuito impreso Revisar conectores en la
defectuoso. placa de circuito
impreso, si el fallo
persiste pngase en
contacto con su
proveedor
El regulador se calienta Bateras demasiado Revise el dimensionado
mucho pequeas y/o muy poco de su instalacin.
consumo.
contacto con su
proveedor.
Hace ruido mecnico Roce entre elementos Coloque y apriete
intermitentemente correctamente los
tornillos de la carcasa.
Ruido interior, revisar si Pngase en contacto
el rotor gira con su proveedor.
correctamente o si los
rodamientos pueden
estar daados.
Hace mucho viento y se Turbulencias. Revise el lugar de
desorienta instalacin de la torre.
constantemente
ESP
1 0.6 1.7 2-6 Ventolina
2 1.8 - 3.3 7 - 12 Suave
3 3.4 - 5.2 13 - 18 Leve
4 5.3 - 7.4 19 - 26 Moderado
5 5.7 - 9.8 27 - 35 Regular
6 9.9 - 10.4 36 - 44 Fuerte
7 12.5 - 15.2 45 - 54 Muy fuerte
8 15.3 - 18.2 55 - 65 Temporal
9 18.3 - 21.5 66 - 77 Temporal fuerte
10 21.6 - 25.1 78 - 90 Temporal muy fuerte *
11 25.2 - 29 91 - 104 Tempestad
12 Ms de 29 Ms de 104 Huracn
*Ante avisos de temporal muy fuerte, Bornay recomienda la parada manual para
una mayor conservacin del aerogenerador.
ESP
aerogeneradores, slu,
DECLARA
Que los aerogeneradores Bornay modelos 600, 1500, 3000, 6000 y sus
correspondientes reguladores, han sido fabricado de conformidad con
las normas aplicables bajo las directivas de la U.E.:
89/392/CEE 91/368/CEE
UNE-EN-61400-2
Bornay Aerogeneradores, slu P.I. Riu, Cno. del Riu, s/n Tel. +34/965560025 bornay@bornay.com
0320 Castalla (Alicante) Espaa Fax +34/965560752 www.bornay.com
GARANTIA LIMITADA
Su nuevo Aerogenerador de la serie Bornay est garantizado contra todo defecto
en material y mano de obra. Esta garanta no cubre daos a otros equipos y / o
accesorios que pudieran verse involucrados en la reparacin del aerogenerador.
La garanta tampoco incluye daos causados por un uso indebido de la
instalacin o el producto.
ESP
CONDICIONES DE LA GARANTA
La garanta incluye piezas y mano de obra siempre en nuestros talleres,
debiendo enviarnos el aerogenerador debidamente embalado y siempre a portes
pagados.
Index 38
Technical data 42
Installation 44
GB
The tower 45
Electrical wiring 46
Regulator 51
Maintenance 62
Troubleshooting 67
Annex 70
Declaration of conformity 73
Warranty 74
Valued Customer,
We want to thank you for purchasing your new Bornay 600 wind turbine and we
hope it will meet all the needs for which you have acquired it and for which we
GB
have produced it.
Warranty conditions are located at the end of this manual. They are dependent
on the proper installation of your wind turbine as this will ensure the correct
functioning of the apparatus and, of course, correct servicing.
We are fully available for consultation should you need any type of information
about your wind turbine or its installation.
Most sincerely
Bornay Aerogeneradores, slu P.I. Riu, Cno. del Riu, s/n Tel. +34/965560025 bornay@bornay.com
03420 Castalla (Alicante) Spain Fax +34/965560752 www.bornay.com
In this manual you will find all the information needed to install and maintain
your windmill. We strongly recommend that you read this manual thoroughly
and understand it before beginning assembly.
At several points in this manual you will find special notes highlighted. These
notes are to be observed with special care because they have critical importance.
Please pay special attention to those points marked with the following example
notices:
CAUTION: WARNING:
system or yourself.
Identification
Each windmill is labeled with its model, voltage and serial number data as it
follows:
Alternator: The wind turbine model, voltage and serial number can be found
on the face of the alternator housing above the brushes cover.
Regulator: On the right side of the control box, there is a sticker indicating
the characteristics, regulator model, windmill model, voltage,
and serial number.
Keep a note of your serial number as this will be useful when you have to order
replacement parts and ask for technical assistance.
Next to this documentation, in the original box, you will find the components
listed below. Some items may already assemble:
1 Tail
1 Tail tube
1 Nacelle
1 Alternator
1 Hub
2 Blades
1 Frontal cone
1 Set of bolts
1 Fixation plate
1 Control box
GB
CONTROL BOX
Bornay 600
Technical specifications
Number of blades 2
Diameter 2 mts.
Material Fiberglass and carbon fiber
Direction of rotation counterclockwise
Electrical specifications
Alternator Three phases permanent magnet
Magnets Ferrite
Nominal power 600 W
GB
Physical specifications
Wind turbine weight 38 Kg
Regulator weight 7 Kgr
Packaging 500 x 770 x 570 mm. 55 Kg
Dimensions weight 1040 x 270 x 70 mm 4,7 Kg
Total 0,22 m3 59,7 Kgr.
Warranty 3 years
GB
Therefore, the best site to install a windmill will be a place where it is exposed
to the most constant and highest wind speed possible. Wind speed depends
enormously on the landscape the air moves over. In almost all locations the
wind speed increases, as you get higher off the ground; vegetation, landscape,
nearby buildings, etc. stop the wind and produce turbulences.
The best place for a wind machine, is an obstruction-free area, and at the
GB
Installation
Before you begin, run through the steps to follow in order to correctly assemble
your wind turbine and take a series of important precautions.
electrical
Tower Windturbine functionality
wiring
installation installation test
controller
In the case of shorter-based towers requiring tensile guy cables: once the base is
anchored and the tower is in place, 3 or 4 tensile guy cables are applied, their
supports firmly anchored to the ground, generally in concrete foundations.
GB
Check at all times that your tower remains perfectly vertical.
The guys ropes have to absorb all tower bend in windy conditions. Therefore,
they must be 6-10 mm diameter steel cables.
Attach the guy wires to the highest point of the
tower but always beneath the diameter of the
blades.
WARNING:
Any object making
contact with the moving
blades can damage and
unbalance them.
Electrical wiring
Full electrical wiring installation must be carried out prior to the installation of
the wind turbine and once the tower has been installed.
CAUTION: WARNING:
Never install the wind turbine Never invert polarity.
if the regulator and batteries
are not properly connected. Use appropriate sized cables.
Different types of batteries exist. In the case of domestic hybrid wind energy/
solar energy installations, open lead-acid batteries are recommended and, to
meet the installations charge capacities, certain minimum installation
requirements are essential to assure correct running and durability of the
installation.
GB
Model Battery Cable Minimum battery size
Bornay 600 / 12V 16 mm2 550 Ah C100
Bornay 600 / 24V 16 mm2 250 Ah C100
Bornay 600 / 48V 10 mm2 150 Ah C100
Bornay 1500 / 24V 25 mm2 660 Ah C100
Bornay 1500 / 48V 16 mm2 350 Ah C100
Bornay 3000 / 24V 35 mm2 1100 Ah C100
Bornay 3000 / 48V 25 mm2 600 Ah C100
Bornay 6000 / 48V 50 mm2 1200 Ah C100
CAUTION: WARNING:
Use of the wrong battery can cause
The use of stationary open lead-acid
irreparable damage to your wind
batteries is recommended.
turbine.
With the correct battery selected and assembled in the installation, the regulator
must now be installed on the wall. This is fixed using the four holes (two upper
and two lower) located in its metallic casing. Fixing is achieved using long
screws and plastic plugs.
Bornay 600 Rev 6.0 - P 47
The regulator has dissipation through internal WARNING:
resistances. The upper part of the regulator
can heat up on windy days once batteries The regulator has internal
have been charged. resistance. Do not cover upper
part.
Do not cover the upper part of the regulator - Install in a well-ventilated
the holes on the top cover must be area.
unobstructed for correct ventilation.
To install the regulator, lift the lower cover from the regulator (only the small
cover which forms a 90 degree angle) by removing the four screws that hold it in
place. This way, the regulator will be positioned as in the following illustration:
WARNING:
DO NOT invert polarity.
+ -
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Battery Battery
Positive Negative
Auxiliar Brake
If, for any reason, the regulator needs to be disconnected, either during
installation or during the useful life of its installation, the following steps must
be observed:
Short circuit the wind turbine, bringing together the three base
connection wires, leaving the wind turbine in braked mode.
Bornay 600 Rev 6.0 - P 49
Double check that the wind turbine is totally braked and disconnects the
wires from the wind turbine.
Disconnect the positive cable from the battery.
Lastly, disconnect the negative cable.
Once the batteries have been installed and connected to the regulator, we will
move on to the wiring between the regulator and the tower top of the tower
where the wind turbine will be installed.
To minimize wire loss, the distance between the wind turbine and the regulation
control box must be as short as possible. Never longer than 100 meters.
To determine the base connection cable gauge for use in line with the
characteristics of the wind turbine and its distance from the control box, see the
following table for copper conducting wire:
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The following table shows conversions between gauges in mm2 and AWG, as
well as the corresponding diameters for these gauges in mm and inches.
mm2 section 4 6 10 16 25 35 50
AWG section 11 9 7 5 3 1 0
Diameter (mm) 2.26 2.76 3.57 4.51 5.64 6.68 7.98
Diameter (in) 0.088 0.108 0.141 0.178 0.222 0.263 0.314
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Regulator
CAUTION: WARNING:
In strong winds, stop the
Never force the rotation of
wind turbine, by switching
the turbine while the brake
the brake on and off several
switch is on.
times.
The regulator, has been specially designed to work with the wind turbines. The
regulator is provided with the following connection switches:
The Control panel looks like the example in the following illustration, in which
the function of each feature can be recognized:
Fan Indicator Brake
Led
Mediun/High
Regulador Inclin
Inclin regulator
Stop
Battery
Led
On
Estable Off
voltage
indicator
Low
Battery Screen LCD
Led Brake
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switch
System functioning:
Basic functioning:
The regulator uses the energy it obtains from the wind turbine to charge
batteries and create electrical energy for the user's consumption. While batteries
are uncharged, and with weather conditions allowing, the regulator supplies
energy to the accumulators.
When the batteries are charged to the pre-programmed setting, the regulator
will cause the wind turbine to go into braked mode to achieve perfect battery
performance and to avoid their deterioration. The way it enters braked mode is
via electrical impulses, i.e. by sending controlled charges to the wind turbine.
System reset:
On connecting the apparatus, or if it is reset for any reason, the regulator will
show a screen, as follows, depending on which model it is:
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The topmost line on the screen shows the regulator model. From left to right it
shows: the wind turbine power; the wind turbine voltage; and the maximum
current it accepts. The bottom line on the screen shows the system version.
NOTE:
If the batteries have become excessively run down for any reason or if regulator
malfunction is detected, RESET can be used to check if the equipment returns to
normal functioning.
To use RESET, there is a printed circuit board micro switch located on the
regulator's control card, i.e. under the regulator cover.
The wind turbine can be braked in a fixed position for several reasons:
When this situation arises, and the automatic braking is active, the status
message appears at the end of the second line on the screen, as in the following
image:
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When the manual braking switch is activated, this is indicated on the screen at
the end of the second line and the brake indication LED is also illuminated.
If the switch is put back to the OFF position, the wind turbine is immediately
freed and newly set to generate energy. The brake indication LED goes off.
This operation must be carried out periodically to verify the correct status of the
braking elements: if, in low wind conditions, the wind turbine does not brake
completely, the electric control box must be checked.
WARNING:
Warning signs:
The regulator detects the voltage at input to the batteries and it carries out
auto-configuration as long as this voltage is permitted within the power
programmed. If the battery voltage is not permitted for the power programmed,
a message appears stating that the voltage is not correct.
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CONFIGURACION
INCORRECTA
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fitted to the tower.
Fixation plate
This joint has two different systems to secure, one has a bolt going through the
tube, and the other one is a flange system. We first introduce the tail tube into
the back side of the alternator, and match the holes in both pieces. We use now
a hexagonal M-8 x 60 bolt, with two M-8 washers, one in each side and an self-
locking M-8 nut. Tighten both to 2,5 Kgr.
Nacelle
On the top of the nacelle there are two holes ready for two M-6 x 15 bolts with
their correspondent wide series M-6 washers and a grover washer, directly
bolted to the alternator bridge. The assembly order is: bolt, grover washer and
wide washer.
Next, the clamp bolt must be tightened at the back part of the nacelle.
Finally, on the lower front side, using the two flanges to anchor, we insert the
brass tube (108 mm long x 10 mm exterior diameter), one M-6 x 130 bolt, with
an M6 wide series washer on each side, on the inner side of the nacelle between
the two flange-forming flaps. Finally, secure using a washer and auto-blocking
nut.
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Blades and frontal cone
The blades, made reinforced carbon fiber/glass make direct contact with the
wind. They are highly stressed. Their aerodynamics, specifically designed for
Bornay wind turbines, makes the alternator turn faster or slower depending on
wind speed.
The next step, having retightened all nuts, is to insert a wide-series M-10 down,
The next step, having retightened all nuts, is to insert a wide-series M-10
washer. These washers will support the frontal nose cone, which is the next part
to install. Once installed, another washer and M-10 self-blocking nut are
applied. Observe the previous illustrations carefully.
CAUTIONN: WARNING:
Check blades are correctly
Double check that blades fit
mounted in the right place;
perfectly and that no
the Bornay logo must be to
obstacle will get in their way.
leeward, on the reverse side
PRECAUTION:
Do not manipulate the windmill and its control panel on windy days.
One month after the installation of the wind turbine, we recommend checking
that the bolts have the right torque and tightening, if necessary.
Periodic maintenance
To ensure long life for your wind turbine, we recommend the following
maintenance schedule:
Each 6 months
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- Checking state of wiring.
- Visual inspection of blades.
- Checking that the automatic breaking system works properly by
tilting it manually.
Bearings
Bornay wind turbines are equipped with great quality sealed bearings which
require no maintenance.. You can check to see if they turn freely or if the
opposite occurs and some kind of friction or vibration is observed.
Bolts
The bolts used in Bornay wind turbines are stainless steel. If a bolt is missing or
in poor condition, it must be replaced right away in order to avoid any breaking
or further damage.
Wiring
All cable connections and switches must be properly checked in order to prevent
any disconnection and to allow the wind turbine to run freely.
Bornay 600 Rev 6.0 - P 62
Blades
The reinforced carbon fiber/glass blades are covered by a protective tape made
of abrasive polyurethane on the leading edges of the blades.
After years of use, this tape may be affected by weather conditions. If the tape is
missing or partially missing, contact your local installation office to have the
tape replaced. By failing to replace the tape, the life of the blade will be seriously
reduced due to the strong erosion the blade is exposed to.
Shock absorber
The wind turbine has one hydraulic shock absorber installed that prevents abrupt
shocks by promoting fast braking and slow return to its original position.
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The shock absorber has a little slack at the beginning of its return movement,
and this is normal. However, if this slack is observed to continue for over half the
return movement, and if oil is leaking, the shock absorber must be replaced.
Lubrication
The front shaft (blades-alternator) is equipped with sealed bearings and covered
with lubricant. It does not need any special attention; its lubricant will last
during its lifetime.
The yawing shaft (windmill-tower) is equipped with sealed bearings and covered
with lubricant. It does not need any special attention; Its lubricant will last
during its lifetime.
3.- Can the battery be disconnected with the wind turbine running?
Under no circumstances, since this action could cause irreparable damage
to the regulator.
4.- Can the regulator cause the batteries to lose their charge?
This is impossible due to the construction of the regulator.
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If it occurs, check your installation because there must be an element that
is discharging the batteries.
5.- The voltage measured by the regulator does not match with the battery level
read by other equipment.
Each manufacturer or even each different apparatus uses different
components, and for reasons of cost these are often not calibrated.
Variations can exist between different equipment, although it is made by
the same manufacturer.
6.- How can I find out what energy the wind turbine is providing?
You simply need to multiply the voltage value and the current (in amps)
shown on the regulator screen.
Energy (W) = Voltage (V) x Amps (A).
8.- How do you know if the wind turbine is providing charge to the batteries?
This shows on the regulator screen that indicates the charge current.
10.- Will one of these wind turbines provide enough power for a home?
This kind of wind turbine is normally used together with other
components to form a complete installation. These components are
usually:
Wind regulator: This is included with the wind turbine and this is what
controls battery life. It ensures that battery voltage does not
surpass dangerous levels. At the same time, it will brake the
machinery when this does occur.
When the installation is for grid connection, the stabilizer is the grid
connection inverter.
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These voltages are later rectified by the regulator passing the power to DC
at 12 Vdc, 24 Vdc, or 48 Vdc to charge batteries, or 120 Vdc to supply the
grid connection inverter.
14.- Should some protection be installed between the wind turbine and the
regulator or between the regulator and the battery?
No, never. The regulator is already carrying out these protective functions.
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Batteries too small Revise size calculations
and/or too little of your installation.
consumption.
Beauforts table is the international reference to classify and define the wind
depending on its speed.
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4 5.3 - 7.4 19 - 26 Moderate breeze
5 5.7 - 9.8 27 - 35 Fresh breeze
6 9.9 - 10.4 36 - 44 Strong breeze
7 12.5 - 15.2 45 - 54 Near gale
8 15.3 - 18.2 55 - 65 Gale*
9 18.3 - 21.5 66 - 77 Strong gale
10 21.6 - 25.1 78 - 90 Storm
11 25.2 - 29 91 - 104 Violent storm
12 More than 29 More than 104 Hurricane
When the wind is eclipsed by the objects it finds in its way, it reduces its speed
and turbulence results. The performance of a windmill installed on the wrong
location will be adversely affected by turbulence and light winds.
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STATES
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That Bornay wind turbine models 600, 1500, 3000, 6000 and their
corresponding regulators, have been produced in compliance with
regulations applicable under the E.U.
directives:
89/392/CEE 91/368/CEE
And in accordance with the safety regulations for small wind power
turbines:
UNE-EN-61400-2
Bornay Aerogeneradores, slu P.I. Riu, Cno. del Riu, s/n Tel. +34/965560025 bornay@bornay.com
0320 Castalla (Alicante) Spain Fax +34/965560752 www.bornay.com
LIMITED WARRANTY
Your new Bornay wind turbine is guaranteed against any material defect. This
warranty does not include other equipment or accessories that could be involved
in repairing the windmill. The warranty does not cover defects or damages
produced by improper use or installation of the product.
WARRANTY CONDITIONS
The Warranty covers parts and labour in our workshops only. The wind turbine
must be returned suitably packaged and at the buyer's expense.
The Warranty does not cover breakage due to incorrect usage or equipment with
signs of manipulation. Shipping is not covered by the Warranty.
Bornay reserves the right to substitute or modify any part should the case call
for such.
Any wind turbine not meeting these conditions will be repaired and shipped at
cost to buyer, with prior authorization from the customer.